Power distribution module for personal recreational vehicle

ABSTRACT

A power distribution module for a personal recreational vehicle includes a housing and a cover. The housing defines an interior and includes a wall having an array of receptacle openings. The receptacle openings are adapted to receive and secure electrical components inside the housing. A distribution harness includes a plurality of electrical conductors and is coupled to the housing wherein the electrical conductors are in electrical communication with the electrical components inside the housing. The power distribution module can optionally include a decal to assist quick and accurate placement of the electrical components during the manufacturing process. A method for producing a personal recreational vehicle having a standardized housing over a range of models. The housing includes a component arrangement guide for locating and installing electrical components.

FIELD OF THE INVENTION

The invention relates generally to personal recreational vehicles, andmore particularly to a power distribution module for use with enginesthat power personal recreational vehicles.

BACKGROUND OF THE INVENTION

Personal recreational vehicles, such as snowmobiles and ATVs, are usedby millions of people for sport and fun. To illustrate, snowmobiling isa sport enjoyed by individuals of all ages and walks of life. Althoughinterest in snowmobiling has traditionally been considerable, in recentyears the sport has seen its popularity soar. For example, according tothe International Snowmobile Manufacturers Association, about 82,000snowmobiles were sold in the United States in 1992. By 1997, that numbertopped 170,000 units.

Similarly, the number of Americans driving off-road vehicles such asATVs increased from 19.4 million in 1983 to 27.9 million in 1995. Theincrease in use of personal recreational vehicles is partly due totechnological advancements of the equipment, advances that have made usesafer and easier for persons of differing levels of ability.

For example, snowmobiles have become more comfortable, responsive andmaneuverable, resulting in a more pleasing and exciting ridingexperience for the driver. One advancement of particular importance isthe improvement in the maneuverability and stability of snowmobiles. Asthese characteristics have advanced, a greater number of individualshave been drawn to the sport. The industry has kept pace with the growthin the sport by expanding the number of models available across a rangeof prices. ATVs have seen similar types of changes and improvements.

The growing popularity of personal recreational vehicles puts anincreased demand on manufacturers to reduce cost of the vehicles. Oneway manufacturers can reduce cost is to standardize components, bothwithin and across a product line. Standardization reduces manufacturingcycle time as well as cost.

All personal recreational vehicles include some type of powerdistribution system for routing and control of power and signalsthroughout the vehicle. The power distribution system usually includes afuse box, with individual fuses blowing when the fuse rated power isexceeded. Other components such as diodes and relays are housed in otherlocations.

For the reasons stated, it is desirable to devise a means by which thepower distribution module can be easily standardized for manufacturing.Additionally, it is also desirable to have a power distribution modulethat includes components other than fuses.

SUMMARY OF THE INVENTION

Against this backdrop, the invention has been created. One aspect of thepresent invention is directed to a power distribution module for apersonal recreational vehicle. The power distribution module includes ahousing defining an interior and including a component attachmentportion and a cover. The housing further includes a plurality ofreceptacle openings in a wall in the component attachment portion, andthe receptacle openings are spaced-apart and adapted for receiving andsecuring electrical components within the housing. The powerdistribution module further includes a distribution harness having aplurality of electrical conductors, wherein the electrical conductorselectrically cooperate with the receptacle openings to connect to theelectrical components, and the conductors are adapted to distributepower.

Another aspect of the present invention is directed to a personalrecreational vehicle having an electrical distribution system fordistributing electrical signals and power. The electrical distributionsystem includes a power distribution module, wherein at least a portionof the electrical signals and power passes through the powerdistribution module. The power distribution module includes a housinghaving a plurality of receptacle openings in a wall, and the receptacleopenings are spaced-apart in an array and adapted for receivingelectrical components. The power distribution module also includes adistribution harness having a plurality of electrical conductors, andthe electrical conductors electrically cooperate with the receptacleopenings for receiving electrical components.

Another aspect of the invention is directed to a power distributionsystem for a personal recreational vehicle including a distributionharness for distributing power and electrical signals adapted to beconnected to electrical components; and means for connecting thedistribution harness to the electrical components.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts an ATV incorporating an example embodiment of the powerdistribution module of the present invention.

FIG. 2 is a perspective view of an example of an embodiment of a powerdistribution module of the present invention.

FIG. 3 is a perspective view from the opposite side of the powerdistribution module of FIG. 2.

FIG. 4 is an elevational view of the cover for a power distributionmodule shown in FIGS. 2 and 3.

FIG. 5 is a top view of the cover of FIG. 4.

FIG. 6 is a bottom view of the cover of FIG. 4.

FIG. 7 is an elevational view of the power distribution module shown inFIGS. 2 and 3.

FIG. 8 is a top view of the power distribution module of FIG. 7.

FIG. 9 is a bottom view of the power distribution module of FIG. 7.

FIG. 10 is an end view of the component attachment module of FIG. 7.

FIG. 11 is a schematic of a decal indicating the layout of electricalcomponents for use in a power distribution module having a 4 by 10 arrayof receptacle openings in accordance with an example embodiment of thepresent invention.

FIG. 12 is a section view of an example embodiment of a catch and latchassembly in the open position for use as a one-handed opening mechanismaccording to the present invention.

FIG. 13 is a section view of an example embodiment of a catch and latchassembly in the open position for use as a one-handed closed mechanismaccording to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

In general, the present disclosure discusses a power distribution modulefor use in a vehicle. The power distribution module tile is capable ofbeing made water-resistant and opens and closes using a one-handedoperation, and includes other desirable properties.

FIG. 1 depicts an ATV 100 with a steering mechanism 102 that controlsthe orientation of a set of front wheels 106 via a steering shaft 104.The steering shaft 104 couples the steering mechanism 102 with the frontwheels 106 via tie rods (not shown) that connect the steering shaft 104to the suspension system (not shown) of the front wheels 106. Thedetails regarding the coupling of the steering shaft 104 and thesuspension system for the wheels 106 vary from ATV to ATV and are knownand are not the focus of the present invention. Therefore, they are notdiscussed further. As the steering mechanism 102 is turned, the frontwheels 106 also turn, thereby controlling the direction in which the ATV100 moves. An engine 108 is mounted toward the front of the chassis ofthe ATV 100. The engine provides power to the drive train (not shown) ofthe ATV 100. The details of the drive train vary from ATV to ATV, butaccording to the present invention, the ATV will have a powerdistribution module 110 to control the flow of power and electricalsignals. The power distribution module will typically be located on aportion of the frame of the ATV near the engine compartment. However,the location can vary depending on the ATV. Similarly, the powerdistribution module of the present disclosure can be used on asnowmobile, and its use and placement are dictated by considerationssimilar to those in using the power distribution in an ATV.

Referring generally to FIGS. 2-10, an example of an embodiment of apower distribution module 210 of the present invention is shown. Powerdistribution module 210 is adapted for housing and securing electricalcomponents to protect them from inclement operating conditions. Powerdistribution module 210 includes a housing 220, the housing 220 definingan interior, and a distribution harness 260. The housing 220 includes acomponent attachment portion 230 adapted to receive and hold electricalcomponents (not shown). Electrical components are held in place inreceptacle openings 232 in a wall 231 of the housing 220. The receptacleopenings 232 are spaced apart and adapted to receive and secureelectrical components within the housing, as will be discussed further.

In the example embodiment shown, the housing 220 includes a componentattachment portion 230 and a removable cover 250. Preferably, when thecover 250 is removably secured to the component attachment portion 230of the housing 220, a waterproof seal is formed, keeping the electricalcomponents protected in the interior of the housing 220 free fromcondensation or other aqueous materials, such as oil or mud, that cancause the electrical components to have a shortened life or fail. One ofskill in the art will recognize that many modifications could be made tomake the housing waterproof, such as a lip and a gasket.

A latch 252 on the cover 250 may engage with a catch 240 on thecomponent attachment portion 230 to removably secure the cover 250 inplace. An advantage of the example embodiment shown is that a user canremove the cover 250 from the component attachment portion 230 usingonly one hand, as will be discussed further below, by disengaging eachlatch 252 from its catch 240. This is especially helpful when accessingthe power distribution module 210, which may not be easily accessible.This allows for easy access to the electrical components in the eventthat one needs to be replaced, since the power distribution module 210is typically located in a small and cluttered space. The cover 250 alsocan be seated in place by engaging one or more stops 238 protruding froman outer surface 237 of the component attachment portion 230. When thecover 250 is secured to the component attachment portion 230, theelectrical components in the interior are protected from the elements.Optionally, one or more mounting brackets 244 can be included on thehousing 220 for connecting to a complementary mating portion (not shown)located on the ATV frame to releasably secure the power distributionmodule 210.

Referring to FIGS. 12-13, shown is an exemplary embodiment of a latch252 and catch 240 arrangement that allows for one-handed removal andplacement of the cover 250 on the component attachment portion 230, suchas that shown in FIGS. 1-2. Catch 240 includes a distal end 281 and aproximal end 282. Proximal end 282 of catch 240 is attached to the cover250. Proximal end 282 includes an arcuate section 283 that forms apocket 284 between depending section 285 of catch 240 and the cover 250.Pocket 284 holds a sealing member 285, for example, a gasket or O-ring.Distal end 281 of catch 240 includes an engagement member 286. Catch 240also includes a resilient portion 287 that allows the distal end 281 ofcatch 240 to move towards and away from the cover 250. The resilientportion 287 biases the catch 240 into an engagement position away fromthe cover 250 when there is no force applied to catch 240. Catch 240also includes a finger engagement portion 288. Force F1 applied to thefinger engagement portion 288 moved the distal end 281 of the catch 240towards the cover 250. Catch 240 includes a flange member 290 extendingfrom the wall of the component attachment portion 230. The flange member290 includes a distal portion 291 located away from the componentattachment portion 230. A protruding shoulder 292 projects from thedistal end 291 of the flange member 290, forming a catch receiving area293 there between. Latch 252 also includes an arcuate section 294 forreceiving into the pocket 284 of catch 240.

FIG. 12 shows the cover 250 and component attachment portion 230 withthe cover 250 disengaged. FIG. 13 shows the cover 250 engaged with thecomponent attachment portion 230, whereby a watertight seal is formed.Beginning from the disengaged position, cover 250 is engaged with thecomponent attachment portion 230 by inserting the distal end 281 of thecatch 240 into the catch receiving area 293 of the latch 252. As thecatch 240 moves into the engagement position with the latch 252, a ramp289 engages the upper end 296 of the shoulder 292, creating an inwardforce F1 that moves the distal end 281 of the catch 240 towards thecover 250. The catch 240 is moved into the catch receiving area 293until the engagement member 286 of the catch 240 clears the lower end295 of the shoulder 292, removing the inward force F1 from the distalend 281 of the catch 240. Upon removal of the force, the resilientportion 287 of the catch 240 returns the catch 240 to the unbiasedposition and the engagement member 286 of the catch 240 engages thelower end 295 of the shoulder 292, securing the cover 250 onto thecomponent attachment portion 230.

A watertight seal is formed by the sealing member 285 being compressedinto the pocket 284 by the arcuate section 294 of the latch 252.Preferably, the pocket 284 runs around the entire periphery of the cover250, and the sealing member 285 is made from one piece of material,minimizing the chance that leak points exist. Compression of the sealingmember 285 also creates a compressive force that holds the engagementmember 286 against the lower end 295 of the shoulder 292, creating aninterference fit that keeps the cover 250 secured.

Referring to FIGS. 1-2 & 12-13, to remove the cover 250 from thecomponent attachment portion 230 via a one-handed operation, a force F2is applied to the finger engagement portion 288 of each catch 240,moving each catch 240 towards the cover 250 until the engagement member286 clears the shoulder 292. The compressive force stored in the sealingmember 285 then moves the cover 250 slightly away from the componentattachment portion 230 and the cover 250 can be completely removed fromthe component attachment portion 230, allowing access to the components.

Referring generally to FIGS. 2-10, the power distribution module 210 maybe mounted to a distribution harness 260. The distribution harness 260includes a plurality of electrical conductors 262, which optionally canbe housed within a sheath 269 to keep the conductors 262 in a bundle.Each electrical conductor 262 optionally may include an insulatingcovering (not shown). Each electrical conductor 262 goes into anassociated receptacle opening 232, and is in electrical communicationwith an electrical component secured into receptacle openings 232 insidethe housing. One or more electrical components are secured into thereceptacle openings 232 in the housing 220. The electrical componentscan be of any type typically used in power distribution systems, such asresistors, capacitors, diodes and fuses.

Referring to FIGS. 2 and 3, the distribution harness 260 preferably issecured to the housing 220 to keep the conductors 262 in an orderlybundle. In the example embodiment shown, a first cable tie 264 secures afirst section 265 of the distribution harness 260 to a first cable tiedown 234 on the component attachment portion 230 of the housing 220, anda second cable tie 266 secures a second section 267 of the distributionharness 260 to a second cable tie down 236 on the component attachmentportion 230 of the housing 220. Optionally, a third cable tie 268 cansecure conductors in the bundle at a third section 269 between the firstand second sections 265, 267 of the distribution harness 260. The thirdcable tie 268 also secures conductors or other elements in thedistribution harness 260 that do not contain termination points into thereceptacle openings 232.

Referring to FIG. 9, in the example embodiment shown, the receptacleopenings 232 are arranged in an array 242 of rows and columns having aregular spacing. The spacing can be selected so that the array 242 isadapted to receive and secure standardized electrical components. Anadvantage of having the array 242 of receptacle openings 232 with aregular spacing pattern is standardized electrical components can belocated and installed easily in the power distribution module.Preferably, the array 242 spacings are identical in the transverse T andlateral L directions. More preferably, the spacing is such that thereceptacle openings 232 are arranged to receive ATO™ or ATC™specification electrical components.

Referring to FIG. 11, a component arrangement guide 300 is shown.Preferably, component arrangement guide 300 is a decal. A decal allowsfor easy identification and location of electrical components acrossproduct and model lines by placing the decal over the receptacle opening(232 as seen in FIGS. 3 and 9). The electrical components can then beeasily located and installed. In the example embodiment shown, componentarrangement guide includes a schematic for placing fuses 302, diodes304, and a relay 306 in the receptacle openings of a power distributionmodule. The use of the decal allows each component to be easily locatedand installed into its proper receptacle opening, and also allows foreasy identification of a specific component location if it needs to bereplaced during maintenance.

An advantage of the power distribution module of the present inventionis that it can be used across a variety of models of personalrecreational vehicle by using a standardized housing common to themodels. A method of producing a plurality of personal recreationalvehicle models is accomplished using the standardized power distributionmodule, thereby saving time and increasing product quality by allowing areduction in inventory of parts specific to each model and also allowingfor accurate placement of the electrical components during assembly. Thepower distribution module includes a plurality of receptacle openingspassing from an interior to an exterior of the housing and is assembledinto the personal recreational vehicle. By placing a componentarrangement guide adjacent the receptacle openings on the interior sideof the housing, the electrical components can be quickly and accuratelyinstalled. The component arrangement guide includes a schematicindicating placement of electrical components. Preferably, the componentarrangement guide is a decal, which can be pre-printed with electricalcomponents arranged for later installation.

When the component arrangement guide is used, the plurality ofelectrical components are installed into the housing into a position inthe receptacle openings as indicated by the component arrangement guide.The electrical components can be installed before or after the powerdistribution module is placed into the personal recreational vehicle.When the electrical components and conductors are installed into thereceptacle openings, each electrical component is electrically connectedto an associated electrical conductor.

Each electrical component can be connected to its respective electricalconductor through its respective receptacle opening by a variety oftechniques known in the art. The preferred method of connecting is tostrip any insulation off the end of the conductor to be inserted into areceptacle opening. The stripped end is inserted into its respectivereceptacle opening. Retention of the stripped end in the receptacleopening can be enhanced by shaping the stripped end to form fingers thatwill snap into one or more recesses in a sidewall of the receptacleopening, thereby locking the stripped end into the receptacle opening.If necessary, removal of the stripped end from its receptacle opening isaccomplished by using an extraction tool that is inserted into thereceptacle opening opposite the electrical conductor side to push theconductor out of the receptacle opening.

Preferably, the electrical conductors are installed before theelectrical components. After each electrical conductor is inserted intoits respective receptacle opening, each electrical component is insertedinto its appropriate location in the power distribution module, asindicated by the component arrangement guide. Preferably, eachelectrical component will have male-blade terminals that are insertedinto their respective receptacle openings and the terminals are heldinto the receptacle openings using a friction or interference fit sothat the electrical components will not fall out during operation. Byusing a friction fit, an operator can remove a defective electricalcomponent using only fingers and no special tool is needed.

It will be clear that the present invention is well adapted to attainthe ends and advantages mentioned as well as those inherent therein.While presently preferred embodiments have been described for purposesof this disclosure, various changes and modifications may be made whichare well within the scope of the present invention. For example, powerdistribution module can include receptacle openings in more than onewall of the housing. Numerous other changes may be made which willreadily suggest themselves to those skilled in the art and which areencompassed in the spirit of the invention disclosed and as defined inthe appended claims.

1. A power distribution module for a personal recreational vehicle comprising: a housing defining an interior, including a component attachment portion and a cover, the housing further including a plurality of receptacle openings in a wall in the component attachment portion, wherein the receptacle openings are spaced-apart and adapted for receiving and securing electrical components within the housing; and a distribution harness having a plurality of electrical conductors, wherein the electrical conductors electrically cooperate with the receptacle openings to connect to the electrical components, wherein the conductors are adapted to distribute power.
 2. The power distribution module of claim 1, wherein the receptacle openings are spaced-apart in an array.
 3. The power distribution module of claim 1, wherein each array has four columns and each column contains ten receptacle openings.
 4. The power distribution module of claim 1, wherein the cover is a removable cover.
 5. The power distribution module of claim 3, wherein the removable cover is removably secured to the component attachment portion with a latch and a catch arrangement.
 6. The power distribution module of claim 3, wherein the cover is removable with one hand by a user.
 7. The power distribution module of claim 1, further including a plurality of electrical components, each electrical component seated in a corresponding receptacle opening, and wherein the electrical components are selected from a group comprising resistors, capacitors, diodes and fuses.
 8. The power distribution module of claim 1, wherein the housing further includes a component arrangement guide located adjacent the wall having the receptacle openings, wherein the component arrangement guide indicates the location of the electrical components to be integrated with the harness.
 9. The power distribution module of claim 9, wherein the component arrangement guide is a decal.
 10. The power distribution module of claim 1, wherein the housing is waterproof when the cover is secured to the component attachment portion.
 11. The power distribution module of claim 1, further including: a plurality of cable ties securing the harness to the housing, a first cable tie securing a first section of the harness to a first tie down, and a second cable tie securing a second section of the harness to a second tie down.
 12. A personal recreational vehicle comprising: an electrical distribution system for distributing electrical signals and power, the electrical distribution system including a power distribution module, wherein at least a portion of the electrical signals and power passes through the power distribution module, the power distribution module including; a housing having a plurality of receptacle openings in a wall, wherein the receptacle openings are spaced-apart in an array and adapted for receiving electrical components; and a distribution harness having a plurality of electrical conductors, wherein the electrical conductors electrically cooperate with the receptacle openings for receiving electrical components.
 13. The personal recreational vehicle of claim 12, wherein the housing further includes: first and second mating portions adapted to be secured together; the first mating portion including a catch; the second mating portion including a latch, wherein the latch engages the catch to secure the first and second portions together when latch and catch are engaged.
 14. The personal recreational vehicle of claim 13, wherein the first and second mating portions form a waterproof interior section when secured together.
 15. The personal recreational vehicle of claim 13, wherein the first and second mating portions are adapted to be disengaged by a user using one hand.
 16. The personal recreational vehicle of claim 12, further including a plurality of electrical components, each electrical component seated in a corresponding receptacle opening, and wherein the electrical components are selected from a group comprising resistors, capacitors, diodes and fuses.
 17. The personal recreational vehicle of claim 12, wherein the housing further includes a component arrangement guide located adjacent the wall having the receptacle openings, wherein the component arrangement guide indicates the location of the electrical components to be integrated with the harness.
 18. The personal recreational vehicle of claim 17, wherein the component arrangement guide is a decal.
 19. A power distribution system for an ATV comprising: a distribution harness for distributing power and electrical signals adapted to be connected to electrical components; and means for connecting the distribution harness to the electrical components.
 20. The power distribution system of claim 19, wherein the means includes first and second mating portions adapted to form a waterproof interior section.
 21. The power distribution system of claim 19, wherein the means includes a plurality of receptacle openings spaced-apart in an array.
 22. The power distribution system of claim 21, wherein the array has four columns and each column contains ten receptacle openings.
 23. A method of producing a plurality of personal recreational vehicle models, each model having a common housing for a power distribution module, wherein the power distribution module includes a plurality of receptacle openings passing from an interior to an exterior of the housing, the method comprising: placing a component arrangement guide adjacent the receptacle openings on the interior side of the housing, the component arrangement guide having a schematic indicating placement of electrical components; installing a plurality of electrical components into a plurality of positions in the receptacle openings, each component being installed in a position indicated by the component arrangement guide; and connecting each electrical component to an associated electrical conductor, each electrical conductor disposed outside the housing.
 24. The method of claim 23, wherein said step of placing the component arrangement guide includes placing a decal.
 25. The method of claim 23, wherein said step of installing includes installing electrical components including at least one fuse and at least one component selected from the group consisting of resistors, capacitors, and diodes. 